2000 DODGE NEON Service Repair Manual

(3) Rotate side gears to opening in differential
(Fig. 129).
(4) Remove differential gears (Fig. 130).INSTALLATION
(1) Assemble the differential side gears, pinion
gears and pinion gears with the pinion gear washers.
(2) Install pinion shaft retaining pin (Fig. 131).
Fig. 129 Remove Pinion Gears, Side Gears, and
Thrust Washers by Rotating Side Gears to Opening
in Case
1 ± DIFFERENTIAL ASSEMBLY
2 ± PINION SHAFT
3 ± SPEEDOMETER DRIVE GEAR
4 ± PINION SHAFT RETAINING PIN
5 ± PINION GEAR (2)
Fig. 130 Differential Gears
1 ± DIFFERENTIAL ASSEMBLY
2 ± PINION SHAFT
3 ± SPEEDOMETER DRIVE GEAR
4 ± SIDE GEAR THRUST WASHERS (SELECT THICKNESS)5 ± PINION GEAR THRUST WASHERS
6 ± PINION GEARS
7 ± SIDE GEARS
8 ± PINION SHAFT RETAINING PIN
Fig. 131 Install Retaining Pin
1 ± PINION SHAFT RETAINING PIN
2 ± SPEEDOMETER DRIVE GEAR
21 - 40 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

(3) Stake pinion shaft retaining pin with a suitable
chisel (Fig. 132).
(4) Rotate the assembly two full revolutions both
clockwise and counterclockwise.
(4) Set up dial indicator as shown and record end
play (Fig. 133) (Fig. 134). Rotate side gear 90 degrees
and record another end play. Again, rotate side gear
90 degrees and record a final end play.
(5) Using the smallest end play recorded, shim
that side gear to within 0.001 to 0.013 inch. The
other side gear should be checked using the same
procedure.CAUTION: Side gear end play must be within 0.001
to 0.013 inch. Five select thrust washers are avail-
able: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.
(6) After the end play is measured and adjusted,
replace speedometer drive gear with a new one.
Install drive gear lip downward. For service informa-
tion, refer to Speedometer Drive Gear service in this
section.
SYNCHRONIZER
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
ASSEMBLY
(1) Position synchronizer hub onto a suitable hold-
ing fixture (input shaft). The synchronizer hubs are
directional. The hubs must be installed with theU
facing upward.
(2) Install springs into hub slot (Fig. 135).
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key (Fig. 136).
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position (Fig. 137).
(6) Line up stop ring tang over the keys in the hub
(Fig. 138). Install stop rings. Center the keys and
balls by pushing on both stop rings.
Fig. 132 Staking Retaining Pin
1 ± PINION SHAFT RETAINING PIN
2 ± SPEEDOMETER DRIVE GEAR
Fig. 133 Checking Side Gear End Play (Typical)
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
4 ± SIDE GEAR
Fig. 134 Checking Side Gear End Play (Typical)
1 ± SPECIAL TOOL C-4996 (NOTE POSITION)
2 ± DIAL INDICATOR SET
3 ± DIFFERENTIAL ASSEMBLY
PLTRANSAXLE 21 - 41
DISASSEMBLY AND ASSEMBLY (Continued)

SHIFT RAILS OVERHAUL
(1) Remove shift rails from the geartrain.
(2) To service the 5-R shift rail, remove the C-clip
retaining the reverse shift lever arm. Remove the 5th
shift fork roll pin and remove the 5th shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.
(3) To service the 3-4 shift rail, remove the roll pin
retaining the 3-4 shift fork. Remove the shift fork.
Remove the shift lug roll pin and remove the shift
lug. Replace parts as necessary.(4) To service the 1-2 shift rail, remove the roll pin
retaining the 1-2 shift fork. Remove the shift fork
and replace parts as necessary.
TRANSAXLE CASE OVERHAUL
The sealant used to seal the transaxle case halves
is MopartGasket Maker, Loctitet518, or equivalent.
The sealant used for the bearing end±plate cover is
MopartRTV.
The components that are left in the gear cases
when the gear train is pulled out are the:
²Axle shaft seals
Fig. 135 Synchronizer Assembly
1 ± SLEEVE
2 ± BALL
3 ± KEY
4 ± SPRING
5 ± HUB
Fig. 136 Synchronizer Balls
1 ± INPUT SHAFT
2 ± HUB
3 ± KEY
4 ± BALL
Fig. 137 Synchronizer Sleeve
1 ± SLEEVE
2 ± INPUT SHAFT
3 ± KEY
Fig. 138 Keys in Hub
1 ± SNAP RING
2 ± CLUTCH
3 ± KEY
4 ± BALL
5 ± SPRING
21 - 42 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

²Output bearing race and retainer
²Input bearing and sleeve
²Differential bearing cones
²Shift rail bushings
²Shift shafts
²Shift shaft seals
²Shift shaft bushings
²Rear bearing oil feed trough
AXLE SHAFT SEALS
REMOVAL
(1) Insert a flat±blade pry tool at outer edge of
axle shaft seal (Fig. 139).
(2) Tap on the pry tool with a small hammer and
remove axle shaft seal.
INSTALLATION
(1) Clean axle shaft seal bore of any excess seal-
ant.
(2) Align axle shaft seal with axle shaft seal bore.
(3) Install axle seal on tool #6709 with C-4171 and
insert into axle shaft seal bore.
(4) Tap seal into position (Fig. 140).
OUTPUT BEARING
REMOVAL
NOTE: The position of the output shaft bearing is
critical. The bearing is not identical end±to±end.
Install bearing with larger diameter cage ring facing
out.(1) Remove caged roller bearing from output bear-
ing race (Fig. 141).
(2) Remove screws at output bearing retainer
strap (Fig. 142).
(3) Install tool #6787 and slide hammer (Fig. 143).
Tighten tool to output bearing race.
(4) Using slide hammer, remove output bearing
race.
Fig. 139 Axle Shaft Seal Removal
1 ± AXLE SEAL
2±PRYTOOL
Fig. 140 Axle Seal Installation
1 ± TOOL C-4171
2 ± TOOL 6709
3 ± AXLE SEAL
Fig. 141 Output Roller Bearing
1 ± INPUT BEARING
2 ± OUTPUT BEARING
3 ± LARGER DIAMETER CAGE RING
PLTRANSAXLE 21 - 43
DISASSEMBLY AND ASSEMBLY (Continued)

INSTALLATION
(1) Line up output bearing race to race bore.
(2) Insert tool #4628 with C-4171 into output bear-
ing race (Fig. 144). Tap race into bore. Install output
bearing into race. Verify that the larger diameter
cage is facing outward. Position bearing retaining
strap. Tighten bolts to 11 N´m (96 in. lbs.).
Fig. 142 Output Bearing Strap
1 ± BEARING RETAINER
2 ± OUTPUT BEARING RACE
Fig. 143 Output Bearing Race Removal
1 ± C-3752
2 ± SPECIAL TOOL 6787
3 ± OUTPUT SHAFT BEARING RACE
Fig. 144 Output Bearing Race Installation
1 ± TOOL C-4171
2 ± TOOL C-4628
3 ± OUTPUT BEARING RACE
21 - 44 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

INPUT BEARING AND SLEEVE
The input bearing is a one±piece bearing and
sleeve unit (Fig. 145). The sleeve is the slide point for
the clutch±release bearing and lever.
REMOVAL
(1) Install tool #6342 over input bearing on the
gear case side of the transaxle clutch housing.
(2) Press the input bearing out of the housing (Fig.
146).INSTALLATION
(1) Apply coating of Loctitetsealant on bearing
outer diameter. Position sleeve and bearing assembly
at input bearing bore.
(2) Install tool #C-4680-1 over input bearing (Fig.
147).
(3) Using the spacer tool #4894 and shop press,
install input bearing into bore until it is fully seated
(Fig. 148).
Fig. 145 Input Bearing And Sleeve
1 ± DIFFERENTIAL BEARING
2 ± OUTPUT BEARING
3 ± INPUT BEARING
4 ± BEARING RETAINER
Fig. 146 Input Bearing Removal
1 ± SPECIAL TOOL 6342
2 ± BELLHOUSING HALF
3 ± INPUT BEARING AND SLEEVE
Fig. 147 Input Bearing Tool
1 ± SPECIAL TOOL C-4680-1
2 ± SPECIAL TOOL 4894
3 ± BELLHOUSING HALF
Fig. 148 Input Bearing Installed
1 ± SLEEVE AND BEARING ASSEMBLY
PLTRANSAXLE 21 - 45
DISASSEMBLY AND ASSEMBLY (Continued)

DIFFERENTIAL BEARING CUPS
REMOVAL
(1) Remove differential assembly from gear case
using the procedure outlined in this group.
(2) Install Miller tool #L-4518 into the differential
bearing cup (Fig. 149).
(3) Install the tool cup over the tool (Fig. 150).
(4) Tighten the tool until the race is removed from
the case.INSTALLATION
(1) Position the bearing cup into the case.
(2) Install the bearing cup onto Miller tool
#L-4520.
(3) Using Miller tool #L-4520 and C-4171 driver,
install differential bearing cup into the transaxle
case.
SHIFT RAIL BUSHINGS
REMOVAL
(1) Thread tool #6786 into shift rail bushing.
(2) Install slide hammer #3752 onto tool.
(3) Remove bushing using slide hammer and tool
assembly (Fig. 151).
INSTALLATION
(1) Line up replacement bushing in bore.
(2) Using tool #MD998343, tap bushing into bore
until flush with the chamfer in the case.
SHIFT SHAFT SEALS
It is not necessary to remove the shift shafts from
the transaxle to service the shift shaft seals.
REMOVAL
(1) Using a pick tool, pry up on the shift shaft seal
and remove seal from bore.
INSTALLATION
(1) Position new shift shaft seal in bore.
(2) Install shift shaft seal into bore using an
appropriate size deep-well socket.
Fig. 149 Tool Installed in Bearing
1 ± SPECIAL TOOL L-4518
2 ± GEAR CASE
Fig. 150 Tool Cup Installed
1 ± GEAR CASE
2 ± SPECIAL TOOL L-4518
3 ± WRENCH
Fig. 151 Shift Rail Bushing Removal
1 ± SPECIAL TOOL 6786
2 ± SLIDE HAMMER C-3752
3 ± SHIFTER RAIL BUSHING
4 ± INPUT BEARING
21 - 46 TRANSAXLEPL
DISASSEMBLY AND ASSEMBLY (Continued)

SHIFT SELECTOR SHAFT
REMOVAL
(1) Disassemble transaxle using the procedure out-
lined in this group.
(2) With the transaxle disassembled, remove the
selector shaft by pushing on the shaft from the out-
side. Pull shaft out from the inside.
INSTALLATION
(1) Reverse removal procedure to install selector
shaft.
SHIFT CROSSOVER SHAFT
REMOVAL
(1) Disassemble transaxle using the procedure out-
lined in this group.
(2) With the transaxle disassembled, remove the
crossover shaft seal.
(3) Using snap±ring pliers, remove the snap ring
at the crossover shaft bore (Fig. 152).
(4) Push the crossover shaft in the case and
remove the crossover assembly.
INSTALLATION
(1) Reverse removal procedure to install crossover
shaft.
SHIFT SELECTOR SHAFT BUSHING
REMOVAL
(1) Remove selector shaft using procedure in this
group.
(2) Thread tool #6786 into bushing.
(3) Install slide hammer #3752 onto tool and
remove bushing using slide hammer (Fig. 153).
INSTALLATION
(1) Position replacement bushing over selector
shaft bore.
(2) Using an appropriate size deep±well socket,
install bushing in selector shaft bore (Fig. 154).
Fig. 152 Crossover Shaft Snap Ring
1 ± SELECTOR SHAFT
2 ± CROSSOVER SHAFT
3 ± SNAP RING
Fig. 153 Selector Shaft Bushing Removal
1 ± SPECIAL TOOL 6786
2 ± SHIFT SHAFT BUSHING
3 ± SLIDE HAMMER C-3752
Fig. 154 Selector Shaft Bushing Installation
1 ± DEEP WELL SOCKET
2 ± SHIFTER SHAFT BUSHING
PLTRANSAXLE 21 - 47
DISASSEMBLY AND ASSEMBLY (Continued)